Komatsu Crawler Dozers D375A-6 60001 and up Workshop Service Manual

Original Illustrated Factory Workshop Service Manual for Komatsu Crawler Dozers D375. 
Original factory manuals for Komatsu Loaders, Dozers, Excavators contains high quality images, circuit diagrams and instructions to help you to operate, maintenance and repair your truck. All Manuals Printable, contains Searchable Text and Navigation Bookmarks
 
Covered models:
    D375A-6 60001 and up
 
Format: PDF, 1735 Pages
Language: English
 
Contents:
    00 Index and Foreword
        Table of contents
        Table of contents 
        Foreword and general information 
        Safety notice 
        How to read the shop manual 
        Explanation of terms for maintenance standard 
        Handling of electric equipment and hydraulic components
        Handling of connectors newly used for engines 
        How to read electric wire code
        Precautions when carrying out work 
        Method of disassembling and connecting push-pull type coupler
        Standard tightening torque table
        List of Abbreviation 
        Conversion table 
    01 Specification
        Specification and technical data
        Specification drawing 
        Specifications
        Weight table 
        Table of fuel, coolant and lubricants 
    10 Structure,function and maintenance standard
        Engine and cooling system 
        Cooling system 
        Cooling fan pump
        Cooling fan motor
        Power train 
        Power train
        Overall drawing of power train unit 
        Power train hydraulic equipment arrangement drawing
        Damper and universal joint 
        Torque converter and PTO 
        Torque converter control valve 
        Main relief valve and torque converter relief valve
        Lockup clutch ECMV and stator clutch ECMV
        Scavenging pump 
        Transmission control
        PCCS lever 
        Transmission
        Transmission ECMV 
        Transmission lubricating oil relief valve 
        Steering and brake control
        Transfer unit, bevel gear shaft and steering 
        Steering control valve 
        Steering clutch ECMV and Steering brake ECMV 
        Parking brake valve 
        Sudden stop prevention valve
        Final drive 
        Undercarriage and frame 
        Track frame
        Idler cushion
        Track roller bogie 
        Main frame 
        Suspension 
        Hydraulic system 
        Work equipment hydraulic piping diagram
        PPC control piping diagram 
        Work equipment control 
        Hydraulic tank 
        Accumulator 
        PPC lock valve
        PPC valve 
        Piston valve
        Quick drop valve 
        Pin puller switch 
        Pin puller solenoid valve 
        Blade control lever (only for the machine with dual tilt specification)
        Work equipment pump
        Control valve 
        Self-pressure reducing valve 
        Work equipment 
        Cylinder stay 
        Cab
        Cab mount 
        Cab 
        Electrical system 
        Engine control 
        Engine control system
        CRI engine control system
        Monitor system
        Machine monitor 
        Lamp system
        Engine preheat (electrical intake air heater) control 
        Palm command control system
        Sensor
        Vehicle health monitoring system (VHMS) 
        ORBCOMM system 
    20 Standard value table
        Standard service value table 
        Standard value table for engine
        Standard value table for machine 
    30 Testing and adjusting
        Tools for testing, adjusting, and troubleshooting
        Diagnosis equipment list
        Engine and cooling system 
        Testing engine speed
        Testing intake air pressure (boost pressure) 
        Testing exhaust temperature 
        Testing exhaust gas color 
        Adjusting valve clearance 
        Measuring compression pressure
        Testing blow-by pressure
        Testing engine oil pressure
        Testing EGR valve drive oil pressure
        Handling of fuel system devices 
        Releasing residual pressure from fuel system
        Testing fuel pressure 
        Handling of reduced cylinder mode operation 
        Handling of no injection cranking operation 
        Testing leakage from pressure limiter and return rate from injector 
        Bleeding air from fuel circuit
        Testing fuel circuit for leakage 
        Replacing and adjusting alternator and air conditioner compressor belt 
        Measuring fan speed 
        Testing fan circuit oil pressure 
        Bleeding air from fan pump
        Adjusting fuel control dial and decelerator pedal 
        Power train 
        Testing power train oil pressure
        Adjusting transmission output speed sensor 
        Simple test procedure for brake performance
        Adjusting brake pedal and parking brake lever
        Adjusting position of pccs lever console 
        Emergency escape method when there is failure in power train 
        Undercarriage and frame 
        Inspecting wear of sprocket 
        Testing and adjusting track shoe tension
        Hydraulic system 
        Measuring and adjusting work equipment oil pressure
        Testing control circuit main pressure 
        Testing PPC valve output pressure 
        Adjusting play of PPC valve
        Testing output pressure of ripper pin-puller solenoid valve 
        Checking location of cause of hydraulic drift of blade and ripper
        Testing leakage inside work equipment cylinder 
        Releasing remaining pressure in work equipment cylinders
        Bleeding air from work equipment cylinders 
        Adjusting ripper lever position
        Work equipment 
        Adjusting work equipment lock lever
        Adjusting blade 
        Cab and its attachments
        Testing and adjusting operator's cab 
        Testing and adjusting operator's seat isolator
        Electrial system 
        Special functions of machine monitor (EMMS) 
        Handling of voltage circuit of engine controller 
        Adjustment method when controller has been replaced 
        Preparation work for troubleshooting of electrical system 
        Inspection procedure of diode
        Handling of optional devices 
        Request for opening ORBCOMM terminal
        Initialization procedures for VHMS controller 
        Using method of KOMTRAX functions of ORBCOMM terminal
        Precautions for replacing VHMS controller 
        Pm Clinic service
    40 Troubleshooting
        General Information on troubleshooting
        Points to remember when troubleshooting 
        Sequence of events in troubleshooting
        Checks before troubleshooting 
        Classification and procedures for troubleshooting 
        Failure codes table
        Phenomena and troubleshooting numbers 
        Information in troubleshooting table
        Troubleshooting method for disconnecting wiring harness of pressure sensor system
        Connectors table and arrangement drawing
        Connection table for connector pin numbers 
        T-branch box and T-branch adapter table 
        Fuse locations table 
        Troubleshooting by failure code 
        Troubleshooting of electrical system (E-mode) 
            Information contained in troubleshooting table 
        Troubleshooting of hydraulic and mechanical system (H-mode) 
            Information in troubleshooting table
            List of Failure Modes and Causes 
        Troubleshooting of engine (S-mode) 
            Method of using troubleshooting chart
        50 Disassembly and assembly
        General information on disassembly and assembly
        How to read this manual 
        Coating materials list
        Special tools list 
        Sketches of special tools 
        Engine and cooling system 
        Removal and installation of fuel supply pump assembly
        Removal and installation of fuel injector assembly 
        Removal and installation of cylinder head assembly 
        Removal and installation of radiator guard assembly 
        Removal and installation of cooling assembly (radiator, after cooler, and hydraulic oil cooler) 
        Removal and installation of radiator
        Removal and installation of hydraulic oil cooler 
        Removal and installation of aftercooler 
        Removal and installation of engineassembly
        Removal and installation of engine hood assembly
        Removal and installation of engine front seal 
        Removal and installation of engine rear seal 
        Removal and installation of fan drive assembly
        Removal and installation of fan motor assembly 
        Removal and installation of fuel tank assembly 
        Power train 
        Removal and installation of damper assembly 
        Disassembly and assembly of damper assembly 
        Removal and installation of power train unit assembly
        Disconnection and connection of power train unit assembly 
        Disassembly and assembly of PTO assembly
        Disassembly and assembly of torque converter assembly 
        Disassembly and assembly of TORQFLOW transmission assembly 
        Disassembly and assembly of steering case assembly
        Removal and installation of power train pump and lubrication pump assembly 
        Removal and installation of scavenging pump assembly
        Removal and installation of final drive assembly 
        Disassembly and assembly of final drive assembly
        Undercarriage and frame 
        Removal and installation of track frame assembly
        Removal and installation of idler assembly
        Disassembly and assembly of idler assembly 
        Removal and installation of recoil spring assembly 
        Disassembly and assembly of recoilspring assembly
        Removal and installation of track roller assembly
        Disassembly and assembly of track roller assembly 
        Removal and installation of carrier roller assembly
        Disassembly and assembly of carrier roller assembly 
        Removal and installation of bogie assembly
        Disassembly and assembly of bogie assembly 
        Removal and installation of first bogie assembly 
        Separation and connection of track shoe assembly 
        Overall disassembly and assembly of track shoe 
        Link press press-fitting jig dimensions 
        Disassembly and assembly of one link assembly in the field 
        Disassembly and assembly of master link 
        Removal and installation of pivot shaft assembly 
        Removal and installation of equalizer bar 
        Disassembly and assembly of equalizer bar bushing 
        Removal and installation of segment tooth 
        Hydraulic system
        Removal and installation of hydraulic tank assembly
        Removal and installation of work equipment pump assembly 
        Removal and installation of fan pump assembly
        Removal and installation of control valve assembly 
        Disassembly and assembly of control valve assembly 
        Disassembly and assembly of blade PPC valve assembly
        Disassembly and assembly of ripper PPC valve assembly
        Disassembly and assembly of hydraulic cylinder assembly
        Disassembly and assembly of ripper pin puller cylinder assembly 
        Work equipment 
        Removal and installation of blade assembly
        Disassembly and assembly of blade assembly 
        Disassembly and assembly of giant ripper assembly 
        Cab and its attachments
        Removal and installation of ROPS guard 
        Removal and installation of operator’s cab assembly
        Removal and installation of floor frame assembly 
        Removal and installation of air conditioner unit assembly 
        Removal and installation of operator's seat isolator
        Disassembly and assembly of operator's seat isolator 
        Electrical system 
        Removal and installation of transmission controller assembly and steering controller assembly
        Removal and installation of engine controller assembly
        Removal and installation of VHMS controller assembly 
        Removal and installation of machine monitor assembly 
    60 Maintenance Standard
        Engine and cooling system 
        Engine mount
        Cooling fan pump
        Cooling fan motor
        Power train 
        Power train unit
        Damper and universal joint 
        Torque converter and PTO 
        Main relief valve and torque converter relief valve
        Lockup clutch ECMV and stator clutch ECMV
        Scavenging pump 
        Transmission control
        Transmission
        Transmission lubricating oil relief valve 
        Power train and lubrication pump 
        Transfer, bevel gear shaft and steering unit 
        Steering control valve 
        Steering clutch ECMV and steering brake ECMV
        Parking brake valve 
        Final drive 
        Sprocket
        Undercarriage and frame 
        Track frame
        Idler cushion
        Idler 
        Track roller 
        Carrier roller 
        Track roller bogie 
        Track shoe 
        Main frame 
        Suspension 
        Hydraulic system 
        PPC valve 
        Hydraulic cylinder
        Quick drop valve 
        Work equipment pump
        Control valve 
        Self-pressure reducing valve 
        Work equipment 
        Cylinder stay 
        Blade
        Cutting edge and end bit
        Ripper 
    80 Appendix
        Air Conditioner
        Caution about refrigerant 
        Air conditioner component 
        Configuration and function of refrigeration cycle
        Outline of refrigeration cycle 
        Air conditioner unit
        Blower unit 
        FRESH/RECIRC air changeover damper 
        Compressor 
        Condenser 
        Receiver drier
        Air conditioner control panel 
        Procedure for testing and troubleshooting 
        Circuit diagram and arrangement of connector pins 
        System diagram
        Part and connector locations 
        Testing temperature control 
        Testing FRESH/RECIC air changeover 
        Testing relay 
        Troubleshooting chart 1 
        Troubleshooting chart 2 
        Information in troubleshooting table
        Troubleshooting for power supply system (Air conditioner does not operate) 
        Troubleshooting for compressor system (Air is not cooled) 
        Troubleshooting for blower motor system (Air does not comeout or air flow is abnormal) 
        Troubleshooting for temperature control
        Troubleshooting for FRESH/RECIRC air changeover 
        Troubleshooting with gauge pressure
        Connection of service tool
        Precautions for disconnecting and connecting 
        Handling of compressor oil 
    90 Diagrams and Drawings
        Hydraulic diagrams and drawings 
        Symbols used in hydraulic circuit diagrams 
        Power train hydraulic circuit diagram 
        Hydraulic circuit diagram
        Electrical diagrams and drawings
        Symbols use in electric circuit diagrams 
        Electrical circuit diagram
    Index
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